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ABB TurbochargingTPL. . -A
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Power, performance and reliabilityHighest engine power and efficiency rely on one vital component – the turbocharger.
The ultimate goals of turbocharged-engine development arehigher power and efficiency – two areas in which ABB’s TPLturbochargers make a vital contribution. The TPL . . -A serieswas developed for modern 4-stroke diesel engines and gasengines for marine (propulsion and auxiliary) applications aswell as for land-based power plants.
The TPL design concept provides a robust and reliable platform for engine applications with outputs ranging from2,500 kW to the highest in the industry. In addition to offeringhigh efficiency and long times between overhauls, these turbochargers have features designed to satisfy strict environ-mental requirements.
A simple, modular design with small number of parts makesthe TPL . . -A easy to maintain and service. Customers benefitfrom low life-cycle costs.
Optimized for today’s marketThe TPL . . -A unites the simplicity and compactness of a modular design with turbine and compressor stages thatensure high turbo charger efficiency while reducing fuel consumption and thermal loading. High volume flow rangesallow optimized matching to different engine applications. A variety of uncooled gas inlet casings and optional wastegate connections are available.
In addition to having a smaller number of parts than its prede-cessor, the TPL . . -A has several new features designed tomake installation and maintenance easier. A major contributorto the turbocharger’s high reliability and long service life is thenew bearing assembly, which is designed for exchange inter-vals of 36,000 hours.
Tested to the limitA comprehensive series of qualification tests is carried out toconfirm the total reliability of ABB turbochargers.
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Benefits that countThe TPL . . -A has a whole range of features designed to keepyour running costs down.
Features Benefits
Radial compressor with backswept blades; different trims available Wide compressor map for optimized matching in all applications
High-performance axial turbine with different stagger angles and trims; Suitable for different turbocharging systems; optimized matching
with lacing wire
Free-floating axial bearing disc; radial bearing bushes High reliability and longer times between overhauls
with squeeze oil damper
Bearing assembly lubricated by engine lube oil system No additional lubrication system needed
Oil inlet and outlet at bottom Easy to service
Turbine and compressor cleaning possible Improved operation in harsh conditions (incl. HFO)
Bearings, rotor, turbine diffuser and nozzle ring dismantled from Simplified maintenance; no need to disconnect hot gas pipes
compressor side
No water cooling No corrosion; no additional piping
Variable positioning of casings and flanges More options for installation
Variable turbine geometry as option Increased operational flexibility
Comprehensive qualification test program, including containment test Highest operational safety
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TurbineThe TPL . . -A turbocharger’s axial turbine is designed for high efficiencies and high volume flow rates. Different staggerangles and the use of lacing wire to damp vibration in thelarger units make the TPL . . -A turbine suitable for pulse aswell as constant pressure turbo charging systems. Variable turbine geometry is available as an option for applications withchanging operating or ambient conditions.
10 12 14 16862 4
Volume flow
V [m3/s]
1.5
1.0
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
�c [-]
Com
pre
ssor
pre
ssur
e ra
tio
Design featuresTurbine and compressor
Turb
ine
effic
ienc
y
90
85
80
75
70
Turbine expansion ratio
1.5 2.52.0 3.0 3.5 �T [-]
�T [%]
Volume flow
3.0
3.5
4.0
4.5
5.0
�c [-]
at M
CR
V [m3/s]
TPL
65TP
L69
TPL
73
TPL
77
TPL
80
5 1510 20
A30
A10
Com
pre
ssor
pre
ssur
e ra
tio
Example of compressor map
CompressorThe high volume flow rates achieved with the TPL . . -A compressor allow optimized matching to different engineapplications. High efficiencies and wide compressor maps are ensured by single-piece, splitter-bladed aluminium alloywheels with backswept blades. Peak efficiencies of more than 85 % are achievable.
Market requirements are covered by two compressor stages.The TPL . . -A10 compressor achieves a pressure ratio of 4.2,high specific flow capacities and high efficiencies. For com-pressor pressure ratios up to 4.5, ABB offers the TPL . . -A30.Titanium compressor wheels are available as an option forspecial applications.
Range of turbine efficiency (2 different flow capacities)
Volume flow range of TPL . . -A turbochargers
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Design featuresBearings and casings
Bearing lifetimeBenefiting from experience gained with over 50,000 ABB turbochargers with plain bearings in service worldwide, TPL plain bearings are designed to run for 36,000 hoursbefore being exchanged.
ABB developed the new bearing assembly for direct lubricationby the engine lube oil system. The main axial bearing consistsof a free-floating thrust disc with profiles on both sides, rotat-ing at about half the rotor speed for minimized losses. Anextremely hard special coating ensures extra-high resistanceto wear caused by contaminated oil. The non-rotating radialbearing bushes are centered in a squeeze oil film damper.
Type A B C D E F G Weight kg*
TPL 65 870 889 1545 600 360 362 458 885
TPL 69 1025 1043 1852 708 424 427 540 1558
TPL 73 1192 1217 2154 822 494 497 627 2310
TPL 77 1416 1446 2539 978 586 589 746 3511
TPL 80 1644 1667 2933 1134 680 684 865 5352
* includes filter silencer
B
GF
A
DE
C
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Optimized casing designTPL . . -A casings have been optimized for applications on 4-stroke engines. Excellent fluid dynamics and minimizedthermal stress are ensured. Features include integrated wastegate flanges, temperature and pressure measurement con-nections. All-round insulation minimizes the turbochargernoise level and casing surface temperature.
ABB turbocharger qualification testsTests include:– Resonance endurance– Low cycle fatigue– Temperature cycle– Hot shutdown– Oil tightness– Compressor containment– Turbine containment– Blade vibration– Thrust bearing– Noise
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AB
B T
urb
o S
yste
ms
Ltd
, B
aden
/Sw
itzer
land
ABB Turbocharging service network
ABB Turbo Systems LtdBruggerstrasse 71 aCH-5401 Baden/SwitzerlandPhone: +41 58 585 7777Fax: +41 58 585 5144E-mail: [email protected]
www.abb.com/turbocharging
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